Compact electric hydraulic fracturing trailer

ABSTRACT

In accordance with one or more embodiments, a compact fracturing system includes a pump truck having a length of at most  40  feet and an electronic system positioned on the pump truck. The electronic system includes a transformer and electronic motor controls housed together with the transformer, and a variable-frequency drive (VFD). The pump trailer further includes a lubrication system having a plurality of sensors, the lubrication system compatible with oil lubrication. In some embodiments, the compact fracturing system includes at least a 3,000 hydraulic horsepower motor drive. In some embodiments, the compact fracturing system includes a quintuplex pump. In some embodiments, the compact fracturing system includes a regulated suction stabilizer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Application No. 62/930,418, filed Nov. 4, 2019, titled “COMPACT ELECTRIC HYDRAULIC FRACTURING TRAILER”, the full disclosure of which is incorporated herein by reference for all purposes.

FIELD OF INVENTION

This invention relates in general to hydraulic fracturing technology, and more particularly to systems and methods pertaining to electric hydraulic fracturing trailers.

BACKGROUND

Hydraulic fracturing has been used for decades to stimulate production from conventional oil and gas wells. The practice consists of pumping fluid into a wellbore at high pressure. Inside the wellbore, the fluid is forced into the formation being produced. When the fluid enters the formation, it fractures, or creates fissures, in the formation. Water, as well as other fluids, and some solid proppants, are then pumped into the fissures to stimulate the release of oil and gas from the formation. Fracturing rock in a formation requires that the fracture fluid be pumped into the wellbore at very high pressure. This pumping is typically performed by large pumps and various other large and heavy equipment. These components are moved and positioned on large heavy duty trailers. In order to carry all the required equipment, conventional trailers are approximately 50 feet in length. Typically, a fracturing operation requires many such trailers to be simultaneously used and located at a job site, thus taking up quite a large footprint among other inefficiencies.

SUMMARY OF THE INVENTION

In accordance with one or more embodiments, a compact fracturing system includes a pump truck having a length of at most 40 feet and an electronic system positioned on the pump truck. The electronic system includes a transformer and electronic motor controls housed together with the transformer, and a variable-frequency drive (VFD). The pump trailer further includes a lubrication system having a plurality of sensors, the lubrication system compatible with oil lubrication. In some embodiments, the compact fracturing system includes at least a 3,000 hydraulic horsepower motor drive. In some embodiments, the compact fracturing system includes a quintuplex pump. In some embodiments, the compact fracturing system includes a regulated suction stabilizer. In some embodiments, the lubrication system is a stroke based packing lubrication system. In some embodiments, the pump truck has a length of at most 37 feet. The electronic system further comprises a housing. The transformer and electric motor controls are housed within the housing. In some embodiments, the compact fracturing system includes a rear mounted power end lube cooler. In some embodiments, the compact fracturing system includes a variable speed cooler motor.

In accordance with another example embodiment, a compact fracturing system includes an electronic system providing power, controls, or both to one or more components of the compact fracturing system. The electronic system includes a transformer, electronic motor controls, and a housing. The electronic motor controls and the transformer are housed together within the housing. In some embodiments, the compact fracturing system further includes a regulated suction stabilizer. In some embodiments, the compact fracturing system further includes a stroke based lubrication system compatible with oil lubricant. In some embodiments, the compact fracturing system further includes a variable speed cooler motor. In some embodiments, the compact fracturing system further includes a 3,000 hydraulic horsepower motor drive. In some embodiments, the compact fracturing system further includes a variable frequency drive (VFD). In some embodiments, the compact fracturing system further includes a quintuplex pump. In some embodiments, the compact fracturing system further includes a rear mounted power end lube cooler. In some embodiments, the electronic system is located on a pump truck have a length of 37 feet or less.

In accordance with another embodiment, a method of hydraulic fracturing includes positioning a compact pump trailer at a pump site. The compact pump trailer has a length below 40 feet. In some embodiments, the pump trailer has a length below 37 feet. The method further includes powering a pump via an electronics system, in which the electronics system includes a transformer and electronic motor controls housed together. In some embodiments, the pump trailer includes a regulated suction stabilizer and a read mounted power end lube cooler. In some embodiments, the pump trailer includes a stroke based lubrication system compatible with oil lubricant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a compact pump trailer 100 (also known as a pump truck) that is a part of a hydraulic fracturing system, in accordance with some embodiments of the present disclosure.

FIG. 2 is a diagram illustrating the electronic system 104, in accordance with example embodiments.

FIG. 3 is a diagram illustrating the instrumented lubrication system 106, in accordance with example embodiments.

FIG. 4 illustrates a method 400 of hydraulic fracturing, in accordance with example embodiments.

DETAILED DESCRIPTION OF THE INVENTION

Electric powered hydraulic fracturing services are a growing part of the broader hydraulic fracturing industry. The ability to power hydraulic fracturing pumps using electric motors, rather than diesel engines or other power sources, provides many advantages. One such advantage is a reduced footprint at a hydraulic fracturing site, due to the omission of bulky diesel motors and other equipment. In fact, some hydraulic fracturing systems can be contained on trailers of 50 feet or less.

The present technology relates to an electric hydraulic fracturing system designed to be more compact than known systems, such that primary components of the system can be mounted on a pump trailer of less than 40 feet, and in some cases less than 37 feet (up to a 23% reduction in trailer size over other electric hydraulic fracturing trailers).

While a more compact trailer provides many advantages, there are technological hurdles to achieving such a reduction in size. For example, pump trailers are used to carry many pieces of equipment and thus must be able to fit and support all of the equipment. Thus, the size of the pump trailer is at least in part dictated by the size and orientation of the onboard equipment. Embodiments of the present disclosure provide solutions to overcome some of these technological challenges.

In some embodiments, the reduction in the length of the pump trailer is at least in part achieved by combining the transformer and electric motor controls, such as the variable frequency drive (VFD) to be housed together. For example, there may be a housing in which the transformer and the electric motor controls are housed. Some embodiments of the technology can also include upgrades to the power end, including a more robust construction to stand up to the harsh working environments throughout the industry.

Some embodiments of the present technology can also include a packing lubrication system that utilizes multiple sensors to lubricate more efficiently. This system improves packing life, reduces waste, and increases operational efficiencies. In addition, the technology can include a design to fit oil lubrication, which reduces the cleanup associated with grease-based systems.

FIG. 1 illustrates a compact pump trailer 100 (also known as a pump truck) that is a part of a hydraulic fracturing system, in accordance with some embodiments of the present disclosure. The pump trailer 100 has a shorter length 102 than conventional pump trailers. In some embodiments, the length 102 of the pump trailer 100 may be less than 40 feet. In some embodiments, the length 102 of the pump trailer 100 may be 37 feet. In some embodiments, the length 102 of the pump trailer 100 may be 36.9 feet. The pump trailer 100 also includes an electronic system 104 in which a transformer and an electronic motor controls are housed together. In some embodiments, the electronic motor controls include a variable-frequency drive (VFD). In some embodiments, the pump trailer 100 further includes at least a 3,000 hydraulic horsepower motor drive 108. In some embodiments, the electronic system 102 includes a housing in which the transformer and the electronic motor controls are housed. In some embodiments, the housing includes one cable plug-in for transmission of power and/or communication signals.

The compact pump trailer 100 also includes a lubrication system 106. The lubrication system 106 is instrumented with a plurality of sensors. The plurality of sensors provides more detailed data which is used to lubricate more effectively and more efficiently. In some embodiments, the lubrication system is compatible with oil lubrication. In some embodiments, the lubrication system is a stroke based packing lubrication system.

In some embodiments, the pump trailer 100 further includes a quintuplex pump 110. In some embodiments, the pump trailer 100 further includes a regulated suction stabilizer 112, which provides smoother flow and reduced vibrations. In some embodiments, the pump trailer 100 further includes a rear mounted power end lube cooler 114. In some embodiments, the pump trailer 100 further includes a variable speed cooler motor 116, which minimizes noise output.

FIG. 2 is a diagram illustrating the electronic system 104, in accordance with example embodiments. As mentioned, the electronic system 104 includes a transformer 202 and electronic motor controls 204 are housed together within a housing 206. In some embodiments, the electronic motor controls include a variable-frequency drive (VFD). In some embodiments, the housing includes one cable plug-in 208 for transmission of power and/or communication signals.

FIG. 3 is a diagram illustrating the instrumented lubrication system 106, in accordance with example embodiments. The lubrication system 106 is instrumented with a plurality of sensors 302. The plurality of sensors 302 provides more detailed data which is used to lubricate more effectively and more efficiently. In some embodiments, the lubrication system 106 is compatible with oil lubrication. In some embodiments, the lubrication system is a stroke based packing lubrication system.

FIG. 4 illustrates a method 400 of hydraulic fracturing, in accordance with example embodiments. The method includes positioning (402) a compact pump trailer at a pump site. The compact pump trailer has a length below 40 feet. In some embodiments, the pump trailer has a length below 37 feet. The method further includes powering (404) a pump via an electronics system. The electronics system includes a transformer and electronic motor controls, in which the transformer and the electronic motor controls housed together, thereby requiring a smaller footprint and allowing the size of the pump trail to be smaller than conventional pump trailers. 

1. A compact fracturing system, comprising: a pump truck having a length of at most 40 feet; an electronic system, comprising: a transformer; electronic motor controls housed together with the transformer; and a variable-frequency drive (VFD); and a lubrication system comprising a plurality of sensors, the lubrication system compatible with oil lubrication.
 2. The compact fracturing system of claim 1, further comprising at least a 3,000 hydraulic horsepower motor drive.
 3. The compact fracturing system of claim 1, further comprising a quintuplex pump.
 4. The compact fracturing system of claim 1, further comprising a regulated suction stabilizer.
 5. The compact fracturing system of claim 1, wherein the lubrication system is a stroke based packing lubrication system.
 6. The compact fracturing system of claim 1, wherein the pump truck has a length of at most 37 feet.
 7. The compact fracturing system of claim 1, wherein the electronic system further comprises a housing, the transformer and electric motor controls housed within the housing.
 8. The compact fracturing system of claim 1, further comprising a rear mounted power end lube cooler.
 9. The compact fracturing system of claim 1, further comprising a variable speed cooler motor.
 10. A compact fracturing system, comprising: an electronic system providing power, controls, or both to one or more components of the compact fracturing system, the electronic system comprising: a transformer; electronic motor controls; and a housing, wherein the electronic motor controls and the transformer are housed within the housing.
 11. The compact fracturing system of claim 10, further comprising a regulated suction stabilizer.
 12. The compact fracturing system of claim 10, further comprising a stroke based lubrication system compatible with oil lubricant.
 13. The compact fracturing system of claim 10, further comprising a variable speed cooler motor.
 14. The compact fracturing system of claim 10, further comprising a 3,000 hydraulic horsepower motor drive.
 15. The compact fracturing system of claim 10, further comprising a variable frequency drive (VFD).
 16. The compact fracturing system of claim 10, wherein the electronic system is located on a pump truck have a length of 37 feet or less.
 17. The compact fracturing system of claim 10, further comprising a quintuplex pump.
 18. The compact fracturing system of claim 10, further comprising a rear mounted power end lube cooler.
 19. A method of hydraulic fracturing, comprising: positioning a compact frac pump trailer at a pump site, the compact frac pump trailer having a length below 37 feet; and powering a pump via an electronics system, the electronics system comprising a transformer and electronic motor controls, the transformer and the electronic motor controls housed together.
 20. The method of claim 18, wherein the frac pump trailer further comprises a regulated suction stabilizer and a read mounted power end lube cooler.
 21. The method of claim 18, wherein the frac pump trailer further comprises a stroke based lubrication system compatible with oil lubricant. 